Compared with traditional plastic forming,ultrasonic vibration plastic forming has the advantages of reducing the forming force and improving the surface quality of the workpiece.This technology has a very broad appli...Compared with traditional plastic forming,ultrasonic vibration plastic forming has the advantages of reducing the forming force and improving the surface quality of the workpiece.This technology has a very broad application prospect in industrial manufactur-ing.Researchers have conducted extensive research on the ultrasonic vibration plastic forming of metals and laid a deep foundation for the development of this field.In this review,metals were classified according to their crystal structures.The effects of ultrasonic vibration on the microstructure of face-centered cubic,body-centered cubic,and hexagonal close-packed metals during plastic forming and the mech-anism underlying ultrasonic vibration forming were reviewed.The main challenges and future research direction of the ultrasonic vibra-tion plastic forming of metals were also discussed.展开更多
In three-dimensional free-bending forming(3D-FBF),the tube is not overly constrained,and the plastic deformation behavior and forming quality of the bent tube are significantly affected by the critical structure of th...In three-dimensional free-bending forming(3D-FBF),the tube is not overly constrained,and the plastic deformation behavior and forming quality of the bent tube are significantly affected by the critical structure of the forming die lining.However,the effects of die-lining structural parameters on the tube quality,and a method to determine the combination of die-lining structural parameters is yet to be devised.This study aims to propose a new framework that allows one to understand the effects of various die-lining structural parameters on tube quality and to propose the best combination of die-lining structural parameters.First,finite-element modeling is performed to simulate 3D-FBF and examine the effects of individual die-lining structures on the quality of tube formation.The simulation results show that the deformation-zone length and die gap are positively correlated with the tube-section distortion and wall-thickness variation,whereas it shows an opposite trend with respect to the bending radius.Additionally,the lining chamfer radius of the bending die and the guide lining chamfer radius minimally affect the tube forming quality.Subsequently,the optimal die-lining structure is obtained using the response-surface method.The tube cross-sectional distortion rate reduced from 2.73 to 2.53%after the die lining is optimized.Additionally,the average inner-wall thickness reduced to 1.06 mm,whereas the average outer-wall thickness increased to 0.97 mm.This paper proposes a method for optimizing the forming-die-lining mechanism and for improving the tube forming quality in 3D-FBF.展开更多
In this research,we present the pure open multi-processing(OpenMP),pure message passing interface(MPI),and hybrid MPI/OpenMP parallel solvers within the dynamic explicit central difference algorithm for the coining pr...In this research,we present the pure open multi-processing(OpenMP),pure message passing interface(MPI),and hybrid MPI/OpenMP parallel solvers within the dynamic explicit central difference algorithm for the coining process to address the challenge of capturing fine relief features of approximately 50 microns.Achieving such precision demands the utilization of at least 7 million tetrahedron elements,surpassing the capabilities of traditional serial programs previously developed.To mitigate data races when calculating internal forces,intermediate arrays are introduced within the OpenMP directive.This helps ensure proper synchronization and avoid conflicts during parallel execution.Additionally,in the MPI implementation,the coins are partitioned into the desired number of regions.This division allows for efficient distribution of computational tasks across multiple processes.Numerical simulation examples are conducted to compare the three solvers with serial programs,evaluating correctness,acceleration ratio,and parallel efficiency.The results reveal a relative error of approximately 0.3%in forming force among the parallel and serial solvers,while the predicted insufficient material zones align with experimental observations.Additionally,speedup ratio and parallel efficiency are assessed for the coining process simulation.The pureMPI parallel solver achieves a maximum acceleration of 9.5 on a single computer(utilizing 12 cores)and the hybrid solver exhibits a speedup ratio of 136 in a cluster(using 6 compute nodes and 12 cores per compute node),showing the strong scalability of the hybrid MPI/OpenMP programming model.This approach effectively meets the simulation requirements for commemorative coins with intricate relief patterns.展开更多
Through exploring the effects of low pH on the composite system of desulfurization gypsum(DG)enhanced by melamine-formaldehyde resin(MF),it is found that the inducing of sulfate-ion,in contrast to chloride and oxalate...Through exploring the effects of low pH on the composite system of desulfurization gypsum(DG)enhanced by melamine-formaldehyde resin(MF),it is found that the inducing of sulfate-ion,in contrast to chloride and oxalate ions,favors the longitudinal growth of the crystalline form of the hydration product,which was relatively simple and had the highest length to width(L/D)ratio.At the same time,MF can also improve L/D ratio of gypsum hydration products,which favors the formation of hydrated whiskers.Finally,in a composite system composed of hemihydrate gypsum,MF,and glass fibers,when dilute sulfuric acid was used to regulate pH=3-4,the tight binding formed among the components of the composite system compared to pH=5-6.The hydration product of gypsum adheres tightly to glass fiber surface and produces a good cross-linking and binding effect with MF.The flexural strength,compressive strength,elastic modulus,and water absorption of the desulphurized gypsum composite board is 22.7 MPa,39.8 MPa,5608 MPa,and 1.8%,respectively.展开更多
A V-shaped bending device was established to evaluate the effects of temperature and bending fillet radius on springback behavior of 2219-W aluminum alloy at cryogenic temperatures.The cryogenic springback mechanism w...A V-shaped bending device was established to evaluate the effects of temperature and bending fillet radius on springback behavior of 2219-W aluminum alloy at cryogenic temperatures.The cryogenic springback mechanism was elucidated through mechanical analyses and numerical simulations.The results indicated that the springback angle at cryogenic temperatures was greater than that at room temperature.The springback angle increased further as the temperature returned to ambient conditions,attributed to the combined effects of the “dual enhancement effect” and thermal expansion.Notably,a critical fillet radius made the springback angle zero for 90° V-shaped bending.The critical fillet radius at cryogenic temperatures was smaller than that at room temperature,owing to the influence of temperature variations on the bending moment ratio between the forward bending section at the fillet and the reverse bending section of the straight arm.展开更多
The bipolar plate(BPP)is a crucial component of proton exchange membrane fuel cells(PEMFC).However,the weight of BPPs can account for around 80%of a PEMFC stack,posing a hindrance to the commercialization of PEMFCs.Th...The bipolar plate(BPP)is a crucial component of proton exchange membrane fuel cells(PEMFC).However,the weight of BPPs can account for around 80%of a PEMFC stack,posing a hindrance to the commercialization of PEMFCs.Therefore,the lightweight design of BPPs should be considered as a priority.Honeycomb sandwich structures meet some requirements for bipolar plates,such as high mechanical strength and lightweight.Animals and plants in nature provide many excellent structures with characteristics such as low density and high energy absorption capacity.In this work,inspired by the microstructures of the Cybister elytra,a novel bio-inspired vertical honeycomb sandwich(BVHS)structure was designed and manufactured by laser powder bed fusion(LPBF)for the application of lightweight BPPs.Compared with the conventional vertical honeycomb sandwich(CVHS)structure formed by LPBF under the same process parameters setting,the introduction of fractal thin walls enabled self-supporting and thus improved LPBF formability.In addition,the BVHS structure exhibited superior energy absorption(EA)capability and bending properties.It is worth noting that,compared with the CVHS structure,the specific energy absorption(SEA)and specific bending strength of the BVHS structure increased by 56.99%and 46.91%,respectively.Finite element analysis(FEA)was employed to study stress distributions in structures during bending and analyze the influence mechanism of the fractal feature on the mechanical properties of BVHS structures.The electrical conductivity of structures were also studied in this work,the BVHS structures were slightly lower than the CVHS structure.FEA was also conducted to analyze the current flow direction and current density distribution of BVHS structures under a constant voltage,illustrating the influence mechanism of fractal angles on electrical conductivity properties.Finally,in order to solve the problem of trapped powder inside the enclosed unit cells,a droplet-shaped powder outlet was designed for LPBF-processed components.The number of powder outlets was optimized based on bending properties.Results of this work could provide guidelines for the design of lightweight BPPs with high mechanical strength and high electrical conductivity.展开更多
Three-dimensional(3D)printing technology has been widely used to create artificial rock samples in rock mechanics.While 3D printing can create complex fractures,the material still lacks sufficient similarity to natura...Three-dimensional(3D)printing technology has been widely used to create artificial rock samples in rock mechanics.While 3D printing can create complex fractures,the material still lacks sufficient similarity to natural rock.Extrusion free forming(EFF)is a 3D printing technique that uses clay as the printing material and cures the specimens through high-temperature sintering.In this study,we attempted to use the EFF technology to fabricate artificial rock specimens.The results show the physico-mechanical properties of the specimens are significantly affected by the sintering temperature,while the nozzle diameter and layer thickness also have a certain impact.The specimens are primarily composed of SiO_(2),with mineral compositions similar to that of natural rocks.The density,uniaxial compressive strength(UCS),elastic modulus,and tensile strength of the printed specimens fall in the range of 1.65–2.54 g/cm3,16.46–50.49 MPa,2.17–13.35 GPa,and 0.82–17.18 MPa,respectively.It is capable of simulating different types of rocks,especially mudstone,sandstone,limestone,and gneiss.However,the simulation of hard rocks with UCS exceeding 50 MPa still requires validation.展开更多
To further investigate the forming mechanism and springback characteristics of strips under multi-square punch forming (MSPF) considering partial-unloading effects, a series of concave form ing tests of strips are con...To further investigate the forming mechanism and springback characteristics of strips under multi-square punch forming (MSPF) considering partial-unloading effects, a series of concave form ing tests of strips are conducted on the MSPF machine. This paper aims to reveal the physical mecha nism of the elastic-plastic deformation in the MSPF process considering the effect of the forming ap proaches, and derive appropriate mathematical interpretations. The theoretical model is firstly estab lished to analyse the concave forming mechanism and springback characteristics of the strip, and its accuracy is then validated by experimental data. The forming history and load evolutions are depicted to explore the required forming capacity through the proposed analytical method. Besides, the paramet ric studies are carried out to discuss their effects on the springback of the strip. The results suggest that the deformation paths of the strip are influenced by the forming approach, and the springback of the strip in convex forming is larger than that in concave forming.展开更多
The impact of cold rolling deformation,which was introduced after solid solution and before aging treatment,on microstructure evolution and mechanical properties of the as-extruded spray formed Al−9.8Zn−2.3Mg−1.73Cu−0...The impact of cold rolling deformation,which was introduced after solid solution and before aging treatment,on microstructure evolution and mechanical properties of the as-extruded spray formed Al−9.8Zn−2.3Mg−1.73Cu−0.13Cr(wt.%)alloy,was investigated.SEM,TEM,and EBSD were used to analyze the microstructures,and tensile tests were conducted to assess mechanical properties.The results indicate that the D1-T6 sample,subjected to 25%cold rolling deformation,exhibits finer grains(3.35μm)compared to the D0-T6 sample(grain size of 4.23μm)without cold rolling.Cold rolling refines the grains that grow in solution treatment.Due to the combined effects of finer and more dispersed precipitates,higher dislocation density and smaller grains,the yield strength and ultimate tensile strength of the D1-T6 sample can reach 663 and 737 MPa,respectively.In comparison to the as-extruded and D0-T6 samples,the yield strength of the D1-T6 sample increases by 415 and 92 MPa,respectively.展开更多
Steve Pennycook is a pioneer in the application of high-resolution scanning transmission electron microscopy(STEM)and in particular the use of annular dark-field(ADF)imaging.Here we show how a general framework for 4D...Steve Pennycook is a pioneer in the application of high-resolution scanning transmission electron microscopy(STEM)and in particular the use of annular dark-field(ADF)imaging.Here we show how a general framework for 4D STEM allows clear links to be made between ADF imaging and the emerging methods for reconstructing images from 4D STEM data sets.We show that both ADF imaging and ptychographical reconstruction can be thought of in terms of integrating over the overlap regions of diffracted discs in the detector plane.This approach allows the similarities in parts of their transfer functions to be understood,though we note that the transfer functions for ptychographic imaging cannot be used as a measure of information transfer.We also show that conditions of partial spatial and temporal coherence affect ADF imaging and ptychography similarly,showing that achromatic interference can always contribute to the image in both cases,leading to a robustness to partial temporal coherence that has enabled high-resolution imaging.展开更多
We investigated the parametric optimization on incremental sheet forming of stainless steel using Grey Relational Analysis(GRA) coupled with Principal Component Analysis(PCA). AISI 316L stainless steel sheets were use...We investigated the parametric optimization on incremental sheet forming of stainless steel using Grey Relational Analysis(GRA) coupled with Principal Component Analysis(PCA). AISI 316L stainless steel sheets were used to develop double wall angle pyramid with aid of tungsten carbide tool. GRA coupled with PCA was used to plan the experiment conditions. Control factors such as Tool Diameter(TD), Step Depth(SD), Bottom Wall Angle(BWA), Feed Rate(FR) and Spindle Speed(SS) on Top Wall Angle(TWA) and Top Wall Angle Surface Roughness(TWASR) have been studied. Wall angle increases with increasing tool diameter due to large contact area between tool and workpiece. As the step depth, feed rate and spindle speed increase,TWASR decreases with increasing tool diameter. As the step depth increasing, the hydrostatic stress is raised causing severe cracks in the deformed surface. Hence it was concluded that the proposed hybrid method was suitable for optimizing the factors and response.展开更多
Aluminum alloy thin-walled structures are widely used in the automotive industry due to their advantages related to light weight and crashworthiness.They can be produced at room temperature by the electrohydraulic for...Aluminum alloy thin-walled structures are widely used in the automotive industry due to their advantages related to light weight and crashworthiness.They can be produced at room temperature by the electrohydraulic forming process.In the present study,the influence of the related parameters on the forming quality of a 6063 aluminum alloy sinusoidal corrugation tube has been assessed.In particular,the orthogonal experimental design(OED)and central composite design(CCD)methods have been used.Through the range analysis and variance analysis of the experimental data,the influence degree of wire diameter(WD)and discharge energy(DE)on the forming quality was determined.Multiple regression analysis was performed using the response surface methodology.A prediction model for the attaching-die state coefficient was established accordingly.The following optimal arrangement of parameters was obtained(WD=0.759 mm,DE=2.926 kJ).The attaching-die state coefficient reached the peak value of 0.001.Better optimized wire diameter and discharge energy for a better attaching-die state could be screened by CCD compared with OED.The response surface method in CCD was more suitable for the design and optimization of the considered process parameters.展开更多
In order to develop the Mg-Zn-Ag metallic glasses(MGs)for biodegradable implant applications,the glass formation ability(GFA)and biocompatibility of Mg-Zn-Ag alloys were investigated using a combination of the calcula...In order to develop the Mg-Zn-Ag metallic glasses(MGs)for biodegradable implant applications,the glass formation ability(GFA)and biocompatibility of Mg-Zn-Ag alloys were investigated using a combination of the calculation of phase diagrams(CALPHAD)and experimental measurements.High GFA potentiality of two alloy series,specifically Mg_(96-x)Zn_xAg_(4)and Mg_(94-x)Zn_xAg_6(x=17,20,23,26,29,32,35),was predicted theoretically and then substantiated through experimental testing.X-ray diffraction(XRD)and differential scanning calorimetry(DSC)techniques were used to evaluate the crystallinity,GFA,and crystallization characteristics of these alloys.The results showed that compositions between Mg_(73)Zn_(23)Ag_(4)and Mg_(64)Zn_(32)Ag_(4)for Mg_(96-x)Zn_xAg_4,Mg_(66)Zn_(28)Ag_(6)and Mg_(63)Zn_(31)Ag_(6for)Mg_(94-x)Zn_xAg_(6)displayed a superior GFA.Notably,the GFA of the Mg_(96-x)Zn_xAg_(4)series was better than that of the Mg_(94-x)Zn_xAg_(6)series.Furthermore,the Mg_(70)Zn_(26)Ag_4,Mg_(74)Zn_(20)Ag_6,and Mg_(71)Zn_(23)Ag_(6)alloys showed acceptable corrosion rates,good cytocompatibility,and positive effects on cell proliferation.These characteristics make them suitable for applications in medical settings,potentially materials as biodegradable implants.展开更多
Hot flow forming(HFF)is a promising forming technology to manufacture thin-walled cylindrical part with longitudinal inner ribs(CPLIRs)made of magnesium(Mg)alloys,which has wide applications in the aerospace field.How...Hot flow forming(HFF)is a promising forming technology to manufacture thin-walled cylindrical part with longitudinal inner ribs(CPLIRs)made of magnesium(Mg)alloys,which has wide applications in the aerospace field.However,due to the thermo-mechanical coupling effect and the existence of stiffened structure,complex microstructure evolution and uneven microstructure occur easily at the cylindrical wall(CW)and inner rib(IR)of Mg alloy thin-walled CPLIRs during the HFF.In this paper,a modified cellular automaton(CA)model of Mg alloy considering the effects of deformation conditions on material parameters was developed using the artificial neural network(ANN)method.It is found that the ANN-modified CA model exhibits better predictability for the microstructure of hot deformation than the conventional CA model.Furthermore,the microstructure evolution of ZK61 alloy CPLIRs during the HFF was analyzed by coupling the modified CA model and finite element analysis(FEA).The results show that compared with the microstructure at the same layer of the IR,more refined grains and less sufficient DRX resulted from larger strain and strain rate occur at that of the CW;various differences of strain and strain rate in the wall-thickness exist between the CW and IR,which leads to the inhomogeneity of microstructure rising firstly and declining from the inside layer to outside layer;the obtained Hall-Petch relationship between the measured microhardness and predicted grain sizes at the CW and the IR indicates the reliability of the coupled FEA-CA simulation results.展开更多
In order to research the feasibility of using the selective adsorption principle to achieve automatic shaping of nano patterns,in this study,using the liquid gallium as the conductive ink and graphene as the printing ...In order to research the feasibility of using the selective adsorption principle to achieve automatic shaping of nano patterns,in this study,using the liquid gallium as the conductive ink and graphene as the printing plate surface,by changing the surface wettability of patterned areas on the nanoscale of graphene printed boards,the automatic formation of liquid gallium patterns on the graphene printed plate surface was simulated.The results indicated that liquid gallium can achieve automatic patterning on the surface of graphene patterned areas;the greater the interaction energy between gallium and carbon atoms,the clearer the pattern;gallium liquid is prone to remain in complex local positions of the pattern,making it difficult to shape the pattern;if the spacing between adjacent pattern lines is too large or too small,it will result in residual gallium liquid between the lines;increasing the thickness of the gallium film will cause the pattern to expand beyond the boundary,but increasing the thickness of the gallium film can also enhance the thickness and uniformity of the pattern lines.In summary,the principle of selective adsorption can be used to achieve the automatic formation of nano patterns,and the pattern formation effect is influenced by factors such as atomic interaction energy and pattern configuration.展开更多
In gas metal arc welding(GMAW)process,the short-circuit transition was the most typical transition observed in molten metal droplets.This paper used orthogonal tests to explore the coupling effect law of welding proce...In gas metal arc welding(GMAW)process,the short-circuit transition was the most typical transition observed in molten metal droplets.This paper used orthogonal tests to explore the coupling effect law of welding process parameters on the quality of weld forming under short-circuit transition,the design of 3 factors and 3 levels of a total of 9 groups of orthogonal tests,welding current,welding voltage,welding speed as input parameters:effective area ratio,humps,actual linear power density,aspect ratio,Vickers hardness as output paramet-ers(response targets).Using range analysis and trend charts,we can visually depict the relationship between input parameters and a single output parameter,ultimately determining the optimal process parameters that impact the single output index.Then combined with gray the-ory to transform the three response targets into a single gray relational grade(GRG)for analysis,the optimal combination of the weld mor-phology parameters as follows:welding current 100 A,welding voltage 25 V,welding speed 30 cm/min.Finally,validation experiments were conducted,and the results showed that the error between the gray relational grade and the predicted value was 2.74%.It was observed that the effective area ratio of the response target significantly improved,validating the reliability of the orthogonal gray relational method.展开更多
The DP1500 steel series successfully produced by Baosteel is a marked improvement over the cold-rolled hot-dip galvanized dual-phase steel series.Sufficient parameter data related to forming characteristics are needed...The DP1500 steel series successfully produced by Baosteel is a marked improvement over the cold-rolled hot-dip galvanized dual-phase steel series.Sufficient parameter data related to forming characteristics are needed for the successful application of dual-phase steel series in engineering structures.Therefore,differences in the mech-anical properties,forming limit,hole expansion ratio,and stretch bend limit of the 1.5 GPa ultrahigh-strength steel,including DP1500,QP1500,and MS1500,have been systematically studied.Results show that the DP1500 exhibits good plastic deformation performance and approximately 5% uniform elongation,and its true major strain minimum on the forming limit curve(FLC_(0)) value is approximately 0.083,which is higher and lower than the FLC_(0) values of MS1500 and QP1500 of the same strength grade,respectively.DP1500 also exhibits good flanging and pore expansion capabilities and superior performance to QP1500 and MS1500.The minimum radius-to-thickness(R/T) ratio(1.4) of DP1500 in the 90° bend tests transverse to the rolling direction is between the R/T ratios of MS1500 and the QP1500.Overall,the formability performance of DP1500 is between that of MS1500 and QP1500.Its excellent crash energy absorption and formability performance render it a suitable structural component,and it has been successfully tested and verified on a typical complex ultrahigh-strength steel skeleton structure.展开更多
It is one concern of the researchers how magnesium(Mg)alloys solidify under different conditions and how their microstructure evolves during solidification,and what are the relationship between the macroscopic propert...It is one concern of the researchers how magnesium(Mg)alloys solidify under different conditions and how their microstructure evolves during solidification,and what are the relationship between the macroscopic properties and various microstructures.Such issues are difficult to be revealed through experiments only,especially for the newly developed Mg alloys,for which there is a lack of more systematic and mature system.However,multi-scale modeling and simulation can promote and deepen our understanding of the microstructure and its deformation mechanism.In this paper,we review and summarize the recent research progress of numerical simulation of Mg alloys in forming and microstructure,namely casting,extrusion,rolling,and welding,using crystal plasticity finite element(CPFEM)and molecular dynamics(DM)methods.Besides,the methods and innovations of modeling are also summarized.Lastly,the paper discusses the development prospects and challenges of the numerical simulation in the field of Mg alloys.展开更多
In this study,the test subjects included the aluminum alloys 2A14 and 5A06,as well as the welding wires ER2319 and ER5356,single laser welding,laser welding with filler wire,laser metal inert gas(laser-MIG)hybrid weld...In this study,the test subjects included the aluminum alloys 2A14 and 5A06,as well as the welding wires ER2319 and ER5356,single laser welding,laser welding with filler wire,laser metal inert gas(laser-MIG)hybrid welding and laser-MIG hybrid welding with filler wire were carried out respectively to research the influence of aluminum alloy base material and welding wire on weld forming charac-teristics.The results show that:under the same test conditions,the penetration of the base material 5A06 is greater than that of 2A14,the maximum is about 51.3%,and the penetration filling ER5356 is greater than that of ER2319,the maximum is about 32.2%;for 2A14 alu-minum alloy,the penetration is basically unchanged after filling with ER5356,and there is a relatively large decrease after filling ER2319,the maximum is about 21.2%;for 5A06 aluminum alloy,the penetration decreases after filling both kinds of welding wire,the penetration achieved with filler wire ER2319 is lower than that of ER5356.At the same time,through the process of laser absorption in different metal materials,it was found that the differences in material composition led to different laser absorption rates,resulting in different energy utiliza-tion,which is an important reason for the correlation between aluminum alloy materials and laser-MIG hybrid welding with filler wire.展开更多
基金supported by the National Key R&D Program of China(No.2022YFE0121300)the Introduction Plan for High end Foreign Experts,China(No.G2023105001L)the Young Foreign Talent Program,China(No.QN2023105001L).
文摘Compared with traditional plastic forming,ultrasonic vibration plastic forming has the advantages of reducing the forming force and improving the surface quality of the workpiece.This technology has a very broad application prospect in industrial manufactur-ing.Researchers have conducted extensive research on the ultrasonic vibration plastic forming of metals and laid a deep foundation for the development of this field.In this review,metals were classified according to their crystal structures.The effects of ultrasonic vibration on the microstructure of face-centered cubic,body-centered cubic,and hexagonal close-packed metals during plastic forming and the mech-anism underlying ultrasonic vibration forming were reviewed.The main challenges and future research direction of the ultrasonic vibra-tion plastic forming of metals were also discussed.
基金Supported by Open Fund of Jiangsu Industrial Perception and Intelligent Manufacturing Equipment Engineering Research Center of China(Grant No.ZK21-05-04)National Natural Science Foundation of China(Grant Nos.52105360,52175328)+1 种基金Fundamental Research Funds for the Central Universities of China(Grant No.NS2022061)Prince Sattam bin Abdulaziz University of Saudi Arabia(Grant No.PSAU/2024/R/1446).
文摘In three-dimensional free-bending forming(3D-FBF),the tube is not overly constrained,and the plastic deformation behavior and forming quality of the bent tube are significantly affected by the critical structure of the forming die lining.However,the effects of die-lining structural parameters on the tube quality,and a method to determine the combination of die-lining structural parameters is yet to be devised.This study aims to propose a new framework that allows one to understand the effects of various die-lining structural parameters on tube quality and to propose the best combination of die-lining structural parameters.First,finite-element modeling is performed to simulate 3D-FBF and examine the effects of individual die-lining structures on the quality of tube formation.The simulation results show that the deformation-zone length and die gap are positively correlated with the tube-section distortion and wall-thickness variation,whereas it shows an opposite trend with respect to the bending radius.Additionally,the lining chamfer radius of the bending die and the guide lining chamfer radius minimally affect the tube forming quality.Subsequently,the optimal die-lining structure is obtained using the response-surface method.The tube cross-sectional distortion rate reduced from 2.73 to 2.53%after the die lining is optimized.Additionally,the average inner-wall thickness reduced to 1.06 mm,whereas the average outer-wall thickness increased to 0.97 mm.This paper proposes a method for optimizing the forming-die-lining mechanism and for improving the tube forming quality in 3D-FBF.
基金supported by the fund from ShenyangMint Company Limited(No.20220056)Senior Talent Foundation of Jiangsu University(No.19JDG022)Taizhou City Double Innovation and Entrepreneurship Talent Program(No.Taizhou Human Resources Office[2022]No.22).
文摘In this research,we present the pure open multi-processing(OpenMP),pure message passing interface(MPI),and hybrid MPI/OpenMP parallel solvers within the dynamic explicit central difference algorithm for the coining process to address the challenge of capturing fine relief features of approximately 50 microns.Achieving such precision demands the utilization of at least 7 million tetrahedron elements,surpassing the capabilities of traditional serial programs previously developed.To mitigate data races when calculating internal forces,intermediate arrays are introduced within the OpenMP directive.This helps ensure proper synchronization and avoid conflicts during parallel execution.Additionally,in the MPI implementation,the coins are partitioned into the desired number of regions.This division allows for efficient distribution of computational tasks across multiple processes.Numerical simulation examples are conducted to compare the three solvers with serial programs,evaluating correctness,acceleration ratio,and parallel efficiency.The results reveal a relative error of approximately 0.3%in forming force among the parallel and serial solvers,while the predicted insufficient material zones align with experimental observations.Additionally,speedup ratio and parallel efficiency are assessed for the coining process simulation.The pureMPI parallel solver achieves a maximum acceleration of 9.5 on a single computer(utilizing 12 cores)and the hybrid solver exhibits a speedup ratio of 136 in a cluster(using 6 compute nodes and 12 cores per compute node),showing the strong scalability of the hybrid MPI/OpenMP programming model.This approach effectively meets the simulation requirements for commemorative coins with intricate relief patterns.
文摘Through exploring the effects of low pH on the composite system of desulfurization gypsum(DG)enhanced by melamine-formaldehyde resin(MF),it is found that the inducing of sulfate-ion,in contrast to chloride and oxalate ions,favors the longitudinal growth of the crystalline form of the hydration product,which was relatively simple and had the highest length to width(L/D)ratio.At the same time,MF can also improve L/D ratio of gypsum hydration products,which favors the formation of hydrated whiskers.Finally,in a composite system composed of hemihydrate gypsum,MF,and glass fibers,when dilute sulfuric acid was used to regulate pH=3-4,the tight binding formed among the components of the composite system compared to pH=5-6.The hydration product of gypsum adheres tightly to glass fiber surface and produces a good cross-linking and binding effect with MF.The flexural strength,compressive strength,elastic modulus,and water absorption of the desulphurized gypsum composite board is 22.7 MPa,39.8 MPa,5608 MPa,and 1.8%,respectively.
基金the financial supports from the National Key Research and Development Program of China (No. 2019YFA0708804)。
文摘A V-shaped bending device was established to evaluate the effects of temperature and bending fillet radius on springback behavior of 2219-W aluminum alloy at cryogenic temperatures.The cryogenic springback mechanism was elucidated through mechanical analyses and numerical simulations.The results indicated that the springback angle at cryogenic temperatures was greater than that at room temperature.The springback angle increased further as the temperature returned to ambient conditions,attributed to the combined effects of the “dual enhancement effect” and thermal expansion.Notably,a critical fillet radius made the springback angle zero for 90° V-shaped bending.The critical fillet radius at cryogenic temperatures was smaller than that at room temperature,owing to the influence of temperature variations on the bending moment ratio between the forward bending section at the fillet and the reverse bending section of the straight arm.
基金Supported by Defense Industrial Technology Development Program of China(Grant No.JCKY2020605C007)Key Research and Development Program of Jiangsu Province of China(Grant Nos.BE2022069,BE2022069-1,BE2022069-3)Aeronautical Science Foundation of China(Grant No.2020Z049052001).
文摘The bipolar plate(BPP)is a crucial component of proton exchange membrane fuel cells(PEMFC).However,the weight of BPPs can account for around 80%of a PEMFC stack,posing a hindrance to the commercialization of PEMFCs.Therefore,the lightweight design of BPPs should be considered as a priority.Honeycomb sandwich structures meet some requirements for bipolar plates,such as high mechanical strength and lightweight.Animals and plants in nature provide many excellent structures with characteristics such as low density and high energy absorption capacity.In this work,inspired by the microstructures of the Cybister elytra,a novel bio-inspired vertical honeycomb sandwich(BVHS)structure was designed and manufactured by laser powder bed fusion(LPBF)for the application of lightweight BPPs.Compared with the conventional vertical honeycomb sandwich(CVHS)structure formed by LPBF under the same process parameters setting,the introduction of fractal thin walls enabled self-supporting and thus improved LPBF formability.In addition,the BVHS structure exhibited superior energy absorption(EA)capability and bending properties.It is worth noting that,compared with the CVHS structure,the specific energy absorption(SEA)and specific bending strength of the BVHS structure increased by 56.99%and 46.91%,respectively.Finite element analysis(FEA)was employed to study stress distributions in structures during bending and analyze the influence mechanism of the fractal feature on the mechanical properties of BVHS structures.The electrical conductivity of structures were also studied in this work,the BVHS structures were slightly lower than the CVHS structure.FEA was also conducted to analyze the current flow direction and current density distribution of BVHS structures under a constant voltage,illustrating the influence mechanism of fractal angles on electrical conductivity properties.Finally,in order to solve the problem of trapped powder inside the enclosed unit cells,a droplet-shaped powder outlet was designed for LPBF-processed components.The number of powder outlets was optimized based on bending properties.Results of this work could provide guidelines for the design of lightweight BPPs with high mechanical strength and high electrical conductivity.
基金financially supported by the Beijing Natural Science Foundation for Young Scientists(Grant No.8214052)the Talent Fund of Beijing Jiaotong University(Grant No.2021RC226)the State Key Laboratory for GeoMechanics and Deep Underground Engineering,China University of Mining and Technology(Grant No.SKLGDUEK2115).
文摘Three-dimensional(3D)printing technology has been widely used to create artificial rock samples in rock mechanics.While 3D printing can create complex fractures,the material still lacks sufficient similarity to natural rock.Extrusion free forming(EFF)is a 3D printing technique that uses clay as the printing material and cures the specimens through high-temperature sintering.In this study,we attempted to use the EFF technology to fabricate artificial rock specimens.The results show the physico-mechanical properties of the specimens are significantly affected by the sintering temperature,while the nozzle diameter and layer thickness also have a certain impact.The specimens are primarily composed of SiO_(2),with mineral compositions similar to that of natural rocks.The density,uniaxial compressive strength(UCS),elastic modulus,and tensile strength of the printed specimens fall in the range of 1.65–2.54 g/cm3,16.46–50.49 MPa,2.17–13.35 GPa,and 0.82–17.18 MPa,respectively.It is capable of simulating different types of rocks,especially mudstone,sandstone,limestone,and gneiss.However,the simulation of hard rocks with UCS exceeding 50 MPa still requires validation.
文摘To further investigate the forming mechanism and springback characteristics of strips under multi-square punch forming (MSPF) considering partial-unloading effects, a series of concave form ing tests of strips are conducted on the MSPF machine. This paper aims to reveal the physical mecha nism of the elastic-plastic deformation in the MSPF process considering the effect of the forming ap proaches, and derive appropriate mathematical interpretations. The theoretical model is firstly estab lished to analyse the concave forming mechanism and springback characteristics of the strip, and its accuracy is then validated by experimental data. The forming history and load evolutions are depicted to explore the required forming capacity through the proposed analytical method. Besides, the paramet ric studies are carried out to discuss their effects on the springback of the strip. The results suggest that the deformation paths of the strip are influenced by the forming approach, and the springback of the strip in convex forming is larger than that in concave forming.
基金the support from the National Natural Science Foundation of China(No.52271177)the Science and Technology Innovation Leaders Projects in Hunan Province,China(No.2021RC4036).
文摘The impact of cold rolling deformation,which was introduced after solid solution and before aging treatment,on microstructure evolution and mechanical properties of the as-extruded spray formed Al−9.8Zn−2.3Mg−1.73Cu−0.13Cr(wt.%)alloy,was investigated.SEM,TEM,and EBSD were used to analyze the microstructures,and tensile tests were conducted to assess mechanical properties.The results indicate that the D1-T6 sample,subjected to 25%cold rolling deformation,exhibits finer grains(3.35μm)compared to the D0-T6 sample(grain size of 4.23μm)without cold rolling.Cold rolling refines the grains that grow in solution treatment.Due to the combined effects of finer and more dispersed precipitates,higher dislocation density and smaller grains,the yield strength and ultimate tensile strength of the D1-T6 sample can reach 663 and 737 MPa,respectively.In comparison to the as-extruded and D0-T6 samples,the yield strength of the D1-T6 sample increases by 415 and 92 MPa,respectively.
基金funding from the European Research Council(ERC)under the European Union’s Horizon 2020 Research and Innovation Programme via Grant Agreement No.802123-HDEM(TJP)from the UK Engineering and Physical Sciences Research Council(EPSRC)via grant EP/M010708/1(PDN).
文摘Steve Pennycook is a pioneer in the application of high-resolution scanning transmission electron microscopy(STEM)and in particular the use of annular dark-field(ADF)imaging.Here we show how a general framework for 4D STEM allows clear links to be made between ADF imaging and the emerging methods for reconstructing images from 4D STEM data sets.We show that both ADF imaging and ptychographical reconstruction can be thought of in terms of integrating over the overlap regions of diffracted discs in the detector plane.This approach allows the similarities in parts of their transfer functions to be understood,though we note that the transfer functions for ptychographic imaging cannot be used as a measure of information transfer.We also show that conditions of partial spatial and temporal coherence affect ADF imaging and ptychography similarly,showing that achromatic interference can always contribute to the image in both cases,leading to a robustness to partial temporal coherence that has enabled high-resolution imaging.
文摘We investigated the parametric optimization on incremental sheet forming of stainless steel using Grey Relational Analysis(GRA) coupled with Principal Component Analysis(PCA). AISI 316L stainless steel sheets were used to develop double wall angle pyramid with aid of tungsten carbide tool. GRA coupled with PCA was used to plan the experiment conditions. Control factors such as Tool Diameter(TD), Step Depth(SD), Bottom Wall Angle(BWA), Feed Rate(FR) and Spindle Speed(SS) on Top Wall Angle(TWA) and Top Wall Angle Surface Roughness(TWASR) have been studied. Wall angle increases with increasing tool diameter due to large contact area between tool and workpiece. As the step depth, feed rate and spindle speed increase,TWASR decreases with increasing tool diameter. As the step depth increasing, the hydrostatic stress is raised causing severe cracks in the deformed surface. Hence it was concluded that the proposed hybrid method was suitable for optimizing the factors and response.
基金supported by National Natural Science Foundation of China(Grant Nos.51975202(Junjia Cui received the grant)and 52175315(Guangyao Li received the grant)).
文摘Aluminum alloy thin-walled structures are widely used in the automotive industry due to their advantages related to light weight and crashworthiness.They can be produced at room temperature by the electrohydraulic forming process.In the present study,the influence of the related parameters on the forming quality of a 6063 aluminum alloy sinusoidal corrugation tube has been assessed.In particular,the orthogonal experimental design(OED)and central composite design(CCD)methods have been used.Through the range analysis and variance analysis of the experimental data,the influence degree of wire diameter(WD)and discharge energy(DE)on the forming quality was determined.Multiple regression analysis was performed using the response surface methodology.A prediction model for the attaching-die state coefficient was established accordingly.The following optimal arrangement of parameters was obtained(WD=0.759 mm,DE=2.926 kJ).The attaching-die state coefficient reached the peak value of 0.001.Better optimized wire diameter and discharge energy for a better attaching-die state could be screened by CCD compared with OED.The response surface method in CCD was more suitable for the design and optimization of the considered process parameters.
基金the financial supports from the Shenzhen Basic Research Project,China(No.JCYJ20170815153210359)the National Natural Science Foundation of China(No.12174210)。
文摘In order to develop the Mg-Zn-Ag metallic glasses(MGs)for biodegradable implant applications,the glass formation ability(GFA)and biocompatibility of Mg-Zn-Ag alloys were investigated using a combination of the calculation of phase diagrams(CALPHAD)and experimental measurements.High GFA potentiality of two alloy series,specifically Mg_(96-x)Zn_xAg_(4)and Mg_(94-x)Zn_xAg_6(x=17,20,23,26,29,32,35),was predicted theoretically and then substantiated through experimental testing.X-ray diffraction(XRD)and differential scanning calorimetry(DSC)techniques were used to evaluate the crystallinity,GFA,and crystallization characteristics of these alloys.The results showed that compositions between Mg_(73)Zn_(23)Ag_(4)and Mg_(64)Zn_(32)Ag_(4)for Mg_(96-x)Zn_xAg_4,Mg_(66)Zn_(28)Ag_(6)and Mg_(63)Zn_(31)Ag_(6for)Mg_(94-x)Zn_xAg_(6)displayed a superior GFA.Notably,the GFA of the Mg_(96-x)Zn_xAg_(4)series was better than that of the Mg_(94-x)Zn_xAg_(6)series.Furthermore,the Mg_(70)Zn_(26)Ag_4,Mg_(74)Zn_(20)Ag_6,and Mg_(71)Zn_(23)Ag_(6)alloys showed acceptable corrosion rates,good cytocompatibility,and positive effects on cell proliferation.These characteristics make them suitable for applications in medical settings,potentially materials as biodegradable implants.
基金supported by the National Nat-ural Science Foundation of China(Grant Nos.51775194 and 52090043).
文摘Hot flow forming(HFF)is a promising forming technology to manufacture thin-walled cylindrical part with longitudinal inner ribs(CPLIRs)made of magnesium(Mg)alloys,which has wide applications in the aerospace field.However,due to the thermo-mechanical coupling effect and the existence of stiffened structure,complex microstructure evolution and uneven microstructure occur easily at the cylindrical wall(CW)and inner rib(IR)of Mg alloy thin-walled CPLIRs during the HFF.In this paper,a modified cellular automaton(CA)model of Mg alloy considering the effects of deformation conditions on material parameters was developed using the artificial neural network(ANN)method.It is found that the ANN-modified CA model exhibits better predictability for the microstructure of hot deformation than the conventional CA model.Furthermore,the microstructure evolution of ZK61 alloy CPLIRs during the HFF was analyzed by coupling the modified CA model and finite element analysis(FEA).The results show that compared with the microstructure at the same layer of the IR,more refined grains and less sufficient DRX resulted from larger strain and strain rate occur at that of the CW;various differences of strain and strain rate in the wall-thickness exist between the CW and IR,which leads to the inhomogeneity of microstructure rising firstly and declining from the inside layer to outside layer;the obtained Hall-Petch relationship between the measured microhardness and predicted grain sizes at the CW and the IR indicates the reliability of the coupled FEA-CA simulation results.
文摘In order to research the feasibility of using the selective adsorption principle to achieve automatic shaping of nano patterns,in this study,using the liquid gallium as the conductive ink and graphene as the printing plate surface,by changing the surface wettability of patterned areas on the nanoscale of graphene printed boards,the automatic formation of liquid gallium patterns on the graphene printed plate surface was simulated.The results indicated that liquid gallium can achieve automatic patterning on the surface of graphene patterned areas;the greater the interaction energy between gallium and carbon atoms,the clearer the pattern;gallium liquid is prone to remain in complex local positions of the pattern,making it difficult to shape the pattern;if the spacing between adjacent pattern lines is too large or too small,it will result in residual gallium liquid between the lines;increasing the thickness of the gallium film will cause the pattern to expand beyond the boundary,but increasing the thickness of the gallium film can also enhance the thickness and uniformity of the pattern lines.In summary,the principle of selective adsorption can be used to achieve the automatic formation of nano patterns,and the pattern formation effect is influenced by factors such as atomic interaction energy and pattern configuration.
基金supported by Major Special Projects of Science and Technology in Fujian Province,(Grant No.2020HZ03018)Natural Science Foundation of Fujian Province(Grant No.2020J01873).
文摘In gas metal arc welding(GMAW)process,the short-circuit transition was the most typical transition observed in molten metal droplets.This paper used orthogonal tests to explore the coupling effect law of welding process parameters on the quality of weld forming under short-circuit transition,the design of 3 factors and 3 levels of a total of 9 groups of orthogonal tests,welding current,welding voltage,welding speed as input parameters:effective area ratio,humps,actual linear power density,aspect ratio,Vickers hardness as output paramet-ers(response targets).Using range analysis and trend charts,we can visually depict the relationship between input parameters and a single output parameter,ultimately determining the optimal process parameters that impact the single output index.Then combined with gray the-ory to transform the three response targets into a single gray relational grade(GRG)for analysis,the optimal combination of the weld mor-phology parameters as follows:welding current 100 A,welding voltage 25 V,welding speed 30 cm/min.Finally,validation experiments were conducted,and the results showed that the error between the gray relational grade and the predicted value was 2.74%.It was observed that the effective area ratio of the response target significantly improved,validating the reliability of the orthogonal gray relational method.
文摘The DP1500 steel series successfully produced by Baosteel is a marked improvement over the cold-rolled hot-dip galvanized dual-phase steel series.Sufficient parameter data related to forming characteristics are needed for the successful application of dual-phase steel series in engineering structures.Therefore,differences in the mech-anical properties,forming limit,hole expansion ratio,and stretch bend limit of the 1.5 GPa ultrahigh-strength steel,including DP1500,QP1500,and MS1500,have been systematically studied.Results show that the DP1500 exhibits good plastic deformation performance and approximately 5% uniform elongation,and its true major strain minimum on the forming limit curve(FLC_(0)) value is approximately 0.083,which is higher and lower than the FLC_(0) values of MS1500 and QP1500 of the same strength grade,respectively.DP1500 also exhibits good flanging and pore expansion capabilities and superior performance to QP1500 and MS1500.The minimum radius-to-thickness(R/T) ratio(1.4) of DP1500 in the 90° bend tests transverse to the rolling direction is between the R/T ratios of MS1500 and the QP1500.Overall,the formability performance of DP1500 is between that of MS1500 and QP1500.Its excellent crash energy absorption and formability performance render it a suitable structural component,and it has been successfully tested and verified on a typical complex ultrahigh-strength steel skeleton structure.
基金supported by the National Natural Science Foundation of China(No.52271091)Natural Science Foundation Project of Ningxia Province(No.2023AAC03324)the National Key Research and Development Program of China(No.2021YFB3701100).
文摘It is one concern of the researchers how magnesium(Mg)alloys solidify under different conditions and how their microstructure evolves during solidification,and what are the relationship between the macroscopic properties and various microstructures.Such issues are difficult to be revealed through experiments only,especially for the newly developed Mg alloys,for which there is a lack of more systematic and mature system.However,multi-scale modeling and simulation can promote and deepen our understanding of the microstructure and its deformation mechanism.In this paper,we review and summarize the recent research progress of numerical simulation of Mg alloys in forming and microstructure,namely casting,extrusion,rolling,and welding,using crystal plasticity finite element(CPFEM)and molecular dynamics(DM)methods.Besides,the methods and innovations of modeling are also summarized.Lastly,the paper discusses the development prospects and challenges of the numerical simulation in the field of Mg alloys.
基金supported by the Henan Science and Technology Plan Joint Fund Project(Key Project)(203ZP20230007).
文摘In this study,the test subjects included the aluminum alloys 2A14 and 5A06,as well as the welding wires ER2319 and ER5356,single laser welding,laser welding with filler wire,laser metal inert gas(laser-MIG)hybrid welding and laser-MIG hybrid welding with filler wire were carried out respectively to research the influence of aluminum alloy base material and welding wire on weld forming charac-teristics.The results show that:under the same test conditions,the penetration of the base material 5A06 is greater than that of 2A14,the maximum is about 51.3%,and the penetration filling ER5356 is greater than that of ER2319,the maximum is about 32.2%;for 2A14 alu-minum alloy,the penetration is basically unchanged after filling with ER5356,and there is a relatively large decrease after filling ER2319,the maximum is about 21.2%;for 5A06 aluminum alloy,the penetration decreases after filling both kinds of welding wire,the penetration achieved with filler wire ER2319 is lower than that of ER5356.At the same time,through the process of laser absorption in different metal materials,it was found that the differences in material composition led to different laser absorption rates,resulting in different energy utiliza-tion,which is an important reason for the correlation between aluminum alloy materials and laser-MIG hybrid welding with filler wire.
